Method of making absorbent core structures with encapsulated superabsorbent material

Abstract

A method of making an absorbent core structure includes meltspinning at least a first layer of fibrous material having a plurality of first portions and a plurality of second portions. A superabsorbent material is deposited between the respective first and second portions of the first layer. The first portions of the first layer are moved with respect to the second portions of the first layer so as to at least substantially encapsulate the deposited superabsorbent material between the respective first and second portions.

1 . A method of making an absorbent core structure, comprising: 
 meltspinning at least a first layer of fibrous material having a plurality of first portions and a plurality of second portions,    depositing a superabsorbent material between the respective first and second portions of the first layer, and    moving the first portions of the first layer with respect to the second portions of the first layer so as to at least substantially encapsulate the deposited superabsorbent material between the respective first and second portions.    
     
     
         2 . The method of  claim 1 , wherein the first and second portions are respectively formed as peaks and valleys and the method further comprises: 
 depositing the superabsorbent material in at least the valleys.    
     
     
         3 . The method of  claim 1 , wherein the first and second portions are respectively formed as peaks and valleys and the method further comprises: 
 depositing the superabsorbent material generally uniformly across the peaks and valleys.    
     
     
         4 . The method of  claim 1 , wherein moving the first portions of the first layer with respect to the second portions of the first layer further comprises: 
 connecting the first layer of fibrous material to a contractable element, and    causing the contractable element to contract.    
     
     
         5 . The method of  claim 4 , wherein the contractable element further comprises a stretched elastic strand.  
     
     
         6 . The method of  claim 4 , wherein the contractable element further comprises a second fibrous layer.  
     
     
         7 . The method of  claim 1 , wherein moving the first portions of the first layer with respect to the second portions of the first layer so as to at least substantially encapsulate the deposited superabsorbent material further comprises: 
 forming the first and second portions generally into tubular structures with at least a portion of the superabsorbent material received within at least some of the tubular structures.    
     
     
         8 . The method of  claim 1 , further comprising: 
 depositing the superabsorbent material onto the first layer of fibrous material with the first layer of fibrous material in a generally flat condition.    
     
     
         9 . The method of  claim 3 , further comprising: 
 depositing the superabsorbent material onto the first layer of fibrous material in discrete, spaced apart amounts.    
     
     
         10 . The method of  claim 8 , further comprising: 
 depositing the superabsorbent material onto the first layer of fibrous material in a generally continuous layer.    
     
     
         11 . The method of  claim 1 , further comprising: 
 securing a second layer of fibrous material to the first layer of fibrous material.    
     
     
         12 . An apparatus for manufacturing an absorbent core structure, comprising: 
 a web configuration device operative to receive a layer of fibrous material and form a plurality of peaks and valleys in the layer of fibrous material,    an applicator device positioned downstream of said web configuration device and operative to deposit a superabsorbent material into at least the valleys in the layer of fibrous material, and    an encapsulation device positioned downstream of said applicator device and operative to close the peaks against one another to thereby at least substantially encapsulate the superabsorbent material within the valleys.    
     
     
         13 . The apparatus of  claim 12 , wherein said web configuration device further comprises first and second rotary members engageable with opposite sides of the layer of fibrous material.  
     
     
         14 . The apparatus of  claim 13 , wherein said encapsulation device further comprises third and fourth rotary members engageable with opposite sides of the layer of fibrous material, said third and fourth rotary members being controlled to operate at a lower speed than said first and second rotary members so as to cause the peaks to close against one another.